Caterpillar Cat GP25N Forklift Lift Trucks Service Repair Manual SN：ET17DL-50001 and up

Page 1

Service Manual

GP15N ET34L-00011-up

GP18N ET34L-40001-up

GP20CN ET34L-60001-up

GP20N ET17DL-00011-up

GP25N ET17DL-50001-up

GP30N ET13FL-00011-up

GP35N ET13FL-50001-up

DP15N ET16D-00011-up

DP18N ET16D-40001-up

DP20CN ET16D-60001-up

DP20N ET18C-00011-up

DP25N ET18C-50001-up

DP30N ET14E-00011-up

DP35N ET14E-50001-up

For use with S4Q2,S4S and K21/K25 Engine Service Manuals.

99719-69110

Chassis & MastMC/FC

GENERAL INFORMATION

GROUP INDEX

Model view,Truck models covered,Serial number locations,Dimensions, Technical data

COOLING SYSTEM

Fan removal and installation,Fan belt inspection and adjustment

ELECTRICAL SYSTEM

CONTROLLERS

POWER TRAIN

POWERSHIFT TRANSMISSION

FRONT AXLE AND REDUCTION DIFFERENTIAL

REAR AXLE

BRAKE SYSTEM

STEERING SYSTEM

HYDRAULIC SYSTEM

MAST AND FORKS

SERVICE DATA

Console box,Chassis electrical devices,Battery maintenance,Electrical system schematic

Main functions,Service tool functions,Input/output monitor,Error codes and troubleshooting

Removal and installation

Torque converter,1-speed transmission,Control valve, Automatic 2-speed transmission

Front tires,Front axle,Reduction and differential

Rear tires,Rear axle,Toe-in,Minimum turning radius

Master cylinder,Wheel cylinders,Wheel brakes,Brake booster

Steering gear,Power cylinder,Flow divider

Hydraulic tank,Gear pump,Control valve,Lift and tilt cylinders, Flow regulator valve,Down safety valve

Simplex mast,Duplex mast,Triplex mast

Maintenance standards,Periodic service chart,Periodic replacement parts,Lubrication instructions,Special tools

GROUP INDEXItems 1 2 3 4 5 6 7 8 9 10 11 12 13
Model View ...............................................................................................1 – 1 Truck Models Covered ...........................................................................1 – 2 Serial Number Locations ......................................................................1 – 3 Dimensions ...............................................................................................1 – 4 Technical Data .........................................................................................1 – 5 1 GENERAL
INFORMATION
1-1 GENERAL INFORMATION Model View MC Truck 210991 FC Truck 210992

GENERAL INFORMATION

Truck Models Covered

This Service Manual furnishes servicing and maintenance information for the following trucks:

Engine controlLPG engineDiesel engine Standard MC/FC (Non-electronic control)

(FC type is used in torque converter model only.)

LPG engine models

Diesel engine models

Electronic controlMC/FC— Truck class Truck model Model codeserial number Engine mounted Truck model Model codeserial number Engine mounted

ET16D-40001-up

ET16D-60001-up

ET17DL-00011-up ET17DL-50001-up

ET13FL-00011-up ET13FL-50001-up

ET18C-00011-up

ET18C-50001-up

1-2
1 ton class GP15N GP18N GP20CN GP20N GP25N GP30N GP35N
ET34L-00011-up ET34L-40001-up ET34L-60001-up
K21 K21 K21 K21 K21 K25 K25 DP15N DP18N DP20CN DP20N DP25N DP30N DP35N
ET16D-00011-up
S4Q2 S4Q2 S4Q2 S4S S4S S4S S4S 2 ton class 3 ton class
ET14E-00011-up ET14E-50001-up

Serial Number Locations

1-3 GENERAL INFORMATION
210993
1-4
Dimensions L I O K C G B H A J P M N D F E 210994
GENERAL INFORMATION
1-5 Ref.ModelGasoline-engine GP15NGP18N No.Truck Diesel-engine (DP15N)(DP18N) Item Truck A Maximum lift3000 (118) B Free lift115 (4.5) C Fork spread (outside)200 to 920 (7.9 to 36.2) D Fork length920 (36.2) E Tilt angle (forward – backward)6°– 12° F Overall length3180 (125.2)3221 (126.8) G Overall width (outside of tires) Single tire1065 (41.9) Dual tire1330 (52.4) H Overall height (to top of mast lowered)1995 (78.5) I Overall height (to top of overhead guard)2065 (81.3) J Overall height (mast extended)4055 (159.6) K Tread (front) Single tire890 (35) Dual tire1025 (40.4) L Tread (rear)900 (35.4) M Wheelbase1400 (55.1) N Front overhang400 (15.7) O Minimum turning radius1950 (76.8)1980 (78) P Underclearance (at frame)150 (5.9)
Unit:mm (in.)
GENERAL INFORMATION Technical Data
1-6
GP20CNGP20NGP25NGP30NGP35N (DP20CN)(DP20N)(DP25N)(DP30N)(DP35AN) 3000 (118.1) 115 (4.5)140 (5.5)150 (5.9) 220 to 1000 (8.7 to 39.4)250 to 1000 (9.8 to 39.4) 920 (36.2)1070 (42.1) 6°– 12° 3279 (129.1)3408 (134.2)3625 (142.7)3795 (149.4)3860 (152) 1065 (41.9)1150 (45.3)1275 (50.2)1290 (50.8) 1480 (58.3)1490 (58.7) 1995 (78.5)2045 (80.5)2180 (85.8) 2065 (81.3)2070 (81.5)2095 (82.5)2105 (82.9) 4055 (159.6)4085 (160.8)4055 (159.6) 890 (35)960 (37.8)1060 (41.7) 1140 (44.9) 900 (35.4)980 (38.6) 1400 (55.1)1600 (63)1700 (66.9) 415 (16.3)455 (17.9)490 (19.3) 2020 (79.5)2200 (86.6)2230 (87.8)2380 (93.7)2440 (96.1) 150 (5.9)160 (6.3)190 (7.5)200 (7.9)
GENERAL INFORMATION
Unit:mm (in.)

COOLING SYSTEM

Specification ............................................................................................2 – 1 Structure ....................................................................................................2 – 2 Removal and Installation ......................................................................2 – 3 Inspection and Adjustment ..................................................................2 – 5 Fan Belt Inspection ....................................................................................2 – 5 Fan Belt Tension ........................................................................................2 – 5 Connecting Radiator Hoses .......................................................................2 – 5 Unit Layout ................................................................................................2 – 5 Coolant ......................................................................................................2 – 6 Radiator Cap .............................................................................................2 – 6 2

Specification

Truck Models 1 ton class2 ton class3 ton class Items

TypeWater-cooled,forced circulation

RadiatorCorrugated fin (pressure) type

Cooling System

Water pumpCentrifugal type

ThermostatWax Pellet Type

2-1
SYSTEM
COOLING

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COOLING SYSTEM Structure

2-2
Hose layout S4Q2 engine K21, K25 engines S4S engine Lower hose Shroud Radiator Upper hose S4Q2, S4S Reservoir tank K21, K25 209611 Fan (directly coupled to engine) 209610

Removal and Installation

Fan Belt Removal

Sequence

1Tension pulley assembly, Bolt

2Fan belt

Start by: Remove the radiator cover.

Suggestion for Removal

(1) Loosen the tension pulley lock bolt by three or four turns. If the bolt is loosened insufficiently,the tension pulley will not be moved.

Note:Do not loosen the lock bolt to such an extent that the bolt would be removed.

(2)M ove the tension pulley fully toward the fan,then remove the belt.

2-3 COOLING SYSTEM
Engine Fan 2 1 209612
Fan
209613
Tension pulley

COOLING SYSTEM Installation

To install,follow the removal sequence in reverse. Also follow the instructions given below.

(1) Before installing the belt,turn the fan to check for smooth rotation. Replace the bearing if it generates abnormal sound.

(2)After installing the belt,push it to make sure that the tension pulley moves,then tighten the pulley lock bolt firmly.

2-4

Inspection and Adjustment

Fan Belt Inspection

(1)Check the belt for contamination with oil,grease and dust. Replace the belt if required. When the contamination is slight,remove it clean with rag or wiping paper. Do not use gasoline,oil or any other solvent to clean the belt.

(2) During engine overhaul or belt tension adjustment, closely check the belt for condition. Replace the belt with a new one if it has any sort of damage.

Fan Belt Tension

Apply a force of 98 N (10 kgf) [22 lbf] perpendicularly to the belt at a point midway between the fan pulley and tension pulley. Adjust the tension so that belt deflection becomes between 11 to 13 mm (0.43 to 0.51 in.).

Connecting Radiator Hoses

When connecting the hoses to the radiator,fit their ends fully on the fittings and secure them with clamps. Tighten the clamp bolts to the torques indicated below. Make sure that each hose is correctly connected and prevented from disconnection by the flare of the fitting. Clamp bolt tightening torques

2-5 COOLING SYSTEM
3.92 to 5.88 N·m Upper and lower hoses(0.4 to 0.59 kgf·m) [2.9 to 4.3 lbf·ft] 2.94 to 4.9 N·m Cooler hose(0.3 to 0.5 kgf·m) [2.2 to 3.6 lbf·ft] Fan pulley Tension pulley 209614 Hose 209615 Standard type Electronic control type 209616
Unit Layout

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